Multi-chamber aircraft part packaging with ordered part arrangement and labeling and methods thereof

ABSTRACT

The embodiments described herein provide packages and methods that can improve the efficiency of repair procedures on complex vehicles such as aircraft. In particular, the packages and methods can reduce the time need by mechanics to perform complex repair procedures, and thus can reduce the costs of such procedures. In general, such an improvement in time and cost efficiency is provided by packaging and labeling the parts for repair in an arrangement that corresponds to the use of such parts in a defined procedure, such as a for repair procedure defined in a component maintenance manual (CMM).

PRIORITY CLAIM

This application claims priority to U.S. Provisional Patent Application No. 62/154,869, filed on Apr. 30, 2015.

TECHNICAL FIELD

Embodiments of the disclosed subject relate generally to parts packaging, and more particularly, embodiments of the subject matter relate to aircraft parts packaging with labeling and methods thereof.

BACKGROUND

As modern vehicles increase in cost and complexity there can be associated increased costs to repair, where such repairs can include typical repairs to fix identified faults but also can include routine maintenance and overhaul. The cost to repair vehicles can be particularly high where labor costs are high. For example, in modern aircraft, the labor costs associated with using properly trained and certified mechanics can be a very significant portion of the overall aircraft repair costs. One way to reduce repair costs is by decreasing the labor time needed for mechanics to perform repair procedures. Thus, for aircraft and other complex vehicles, it is desirable to reduce the labor time needed for repair procedures to reduce the costs associated with such repair procedures.

BRIEF SUMMARY

In one embodiment, a package is provided that comprises: a package body, the package body including a package face; a plurality of chambers defined in the package body, each of the plurality of chambers configured to contain at least one vehicle part; and a plurality of part identifiers, each of the plurality of part identifiers identifying one of a plurality of vehicle parts, the plurality of part identifiers arranged on the package face with each of the plurality of part identifiers proximate to a corresponding one of the plurality of chambers to identify a corresponding vehicle part, and where the plurality of part identifiers are arranged in an order on the package face corresponding to an order of use during a vehicle repair.

In another embodiment, a method is provided, comprising: providing a package, the package including a package face and a plurality of chambers, each of the plurality of chambers configured to contain at least one vehicle part; placing at least on vehicle part in each of the plurality of chambers; and affixing a plurality of part identifiers to the package face, each of the plurality of part identifiers identifying one of a plurality of vehicle parts, and wherein the plurality of part identifiers are arranged on the package face with each of the plurality of part identifiers proximate to a corresponding one of the plurality of chambers to identify a corresponding vehicle part, and wherein the plurality of part identifiers are arranged in an order on the package face corresponding to an order of use during a vehicle repair.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a parts package in accordance with an exemplary embodiment;

FIG. 2 is a flow diagram of a packaging method accordance with an exemplary embodiment;

FIG. 3, a schematic diagram illustrates an exemplary relationship between an aircraft part, manual page, and corresponding label; and

FIGS. 4, 5 and 6 are perspective view of an exemplary package in accordance with the embodiments described herein.

DETAILED DESCRIPTION

The embodiments described herein provide packages and methods that can improve the efficiency of repair procedures on complex vehicles such as aircraft. In particular, the packages and methods can reduce the time need by mechanics to perform complex repair procedures, and thus can reduce the costs of such procedures, where such repair procedures can include any type of repair, from routine maintenance to complete overhaul. In general, such an improvement in time and cost efficiency is provided by packaging and labeling the parts for repair in an arrangement that corresponds to the use of such parts in a defined procedure, such as a repair procedure defined in a component maintenance manual (CMM). Thus, as a mechanic works through a defined procedure, the order of the work specified in the defined procedure is reflected in the arrangement of the parts in the package. Because the arrangement of the parts in the package reflects the order of the steps in the defined procedure, the mechanic will be more likely to quickly locate a part as needed for the next step in the defined procedure. This will allow the mechanic to quickly obtain and use the parts as needed for the steps in the defined procedure. Such a time savings in locating and obtaining parts builds as the repair continues, and the more complex and more parts used in the procedure the greater the time that may be saved.

Turning to FIG. 1, an exemplary package 100 is illustrated. The package 100 includes a package body 102 and a package face 103. A plurality of chambers 104 are defined in the package body 102, with each of the plurality of chambers 104 configured to contain at least one vehicle part separate from other parts in the package body 102. A plurality of labels 106 are each affixed to the package face 103. Each of the package labels 106 identifies one of the parts in the package body 102, and the labels are affixed to the package face 103 proximate to the chamber containing the corresponding part. To facilitate time efficient use, the package labels 106 and the parts in the chambers 104 are arranged in an order of use in a defined repair procedure that utilizes the plurality of parts. For example, the labels 106 and parts in the chambers 104 can be arranged in an order of use defined by a component maintenance manual (CMM) that describes a repair procedure that uses the plurality of parts.

For example, FIG. 1 illustrates an exemplary repair procedure parts usage order. In this simplified example, the parts are listed in the order in which they would be used by a mechanic following the repair procedure outlined by the component maintenance manual. For example, in the assembly or overhaul process for an aircraft as dictated by the component maintenance manual. To facilitate time efficient repair, the parts are arranged in the chambers 104 and the labels 106 are attached to the package face 103 in the order that corresponds to the order in which they would be used when following the defined repair procedure. Thus, the mechanic can easily find and retrieve the next part to be used to during the repair procedure. It should be noted that in this illustrated example the parts are ordered like a book, i.e., left to right and top to bottom.

However, this is just one example as to how the package labels 106 and parts can be ordered in a way that corresponds to the defined repair procedure. As other examples, the package labels 106 and parts could be arranged in an order from the top to bottom of the package body 102, e.g., in columns with each column corresponding to a portion of the order of use in the defined repair procedure.

Furthermore, in some examples multiple package bodies 102 may be needed to store the parts for the defined repair procedure. In such an embodiment, the package bodies 102 can be configured to fit together inside a larger package for storage and delivery. For example, the package bodies can be configured to stack inside the larger outer package. In such an arrangement, the parts could be arranged with different types of parts in different package bodies 102. For example, with hard parts (e.g., metal and hard plastic parts) stored in one package body 102 while soft parts (e.g., rubber and fiber parts) are storied in the other package body 102. In such a configuration the overall arrangements of the package labels 106 and parts will reflect the order of the steps in the defined repair procedure, with some alternating between package bodies 102 depending on the type of next part needed for the defined repair procedure.

It should be noted that a variety of techniques can be used to further improve the work efficiency of mechanics using the package 100 to perform a repair procedure. For example, the package labels 106 and the component maintenance manual can each be made to include visual indicators that correspond to each other. These corresponding visual indicators provide visual clues to the mechanic to assist in locating a part associated with the next step in the repair procedure. As one example, the various repair steps described in the component maintenance manual and the corresponding package labels 106 can each include the same character, color and/or shape identifier. Including the same character, color and/or shape identifier in both the package label 106 and the corresponding step in the component maintenance manual facilitates the likelihood that the mechanic will quickly locate and obtain the next part when starting the corresponding next step in the procedure. For example, a mechanic preparing to perform step 5 of a repair procedure would see a specific character identifier in the manual at the description of step 5, and a corresponding character in the label identifying the location of the part used in step 5 in the package. Thus, having the same or similar visual identifier on the package label 106 as at the corresponding step in the component maintenance manual would facilitate the quick and accurate selection of the part for step 5 by the mechanic.

In some embodiments additional elements may be incorporated into the package 100 and package labels 106. For example, machine readable codes (e.g., QR codes, bar codes) and other identifiers (e.g., RFID) tags can be used on the package to provide additional information to the mechanic and other users. As one example, a QR code can be added to the package face that when scanned prompts a system to open the appropriate repair manual. In other embodiments such codes can be added to each package label 106.

It should also be noted that the selection of parts in the package and the corresponding repair procedure can be derived in a variety of ways. For example, the selection of parts used during a repair can be based on engineering reliability data associated with the corresponding repairs. Such reliability data can be used to determine which parts should be replaced during which repairs in a way that reduces costs and improves efficiency and reliability. Including such parts that are determined to be desirable to replace during a defined repair procedure ensures that these parts are available to the mechanic during such a repair. Thus, the mechanic is provided with the parts that should be replaced during such a procedure, while unneeded additional parts are not provided.

The use of such packaging can increase shop efficiency, quality, and throughput yield. Additionally, the use of the package can reduce wasteful activities performed in a shop, and thus reduce the hidden factory in the shop. Additionally, the use of such packaging can provide for standardization of parts used within a procedure, which can also improve quality and traceability. The standardization of parts used for a procedure can also reduce the resources needed for ordering, receiving and storing parts, and can thus reduce associated costs.

Such packages can thus provide a significant advantage over packages of parts that are not organized in manner corresponding to the repair procedure defined in a component maintenance manual or other repair procedure. Additionally, the use of such packages can help ensure that repairs are performed correctly, with all appropriate parts replaced, and thus can help standardize what parts are replaced during defined procedures.

Turning to FIG. 2, an exemplary method 200 is illustrated. Step 202 of method 200 is to provide a package that includes a plurality of chambers. The plurality of chambers can be defined in the package using any suitable structure and technique. For example, a plurality of chamber openings can be made in the package face using computer controlled cuts. Specifically, the chambers in the package can be made using precision cuts via a computerized 2D profile. Inserts can then be affixed in the package body to define interior walls of each of the chamber. Such inserts can be separately installed for each chamber, or installed all together. Additionally, such inserts can be implemented in cardboard with molded pulp or dies. The size and shape of the package and inserts can depend on a variety of factors. For example, the package can be sized and shaped to fit within a mechanic workbench real-estate. Regardless of the technique used, each of the chambers is configured to contain at least one vehicle part. In some embodiments the package body can be implemented with recyclable materials.

The step next 204 is to place aircraft parts in the each of the plurality chambers of proximate to a chamber. The next step 206 is to affix part labels to the package face, with each of the part labels proximate a corresponding chamber. In performing steps 204 and 206, the parts and part labels are arranged in an order corresponding to the order of use in a defined repair procedure. For example, in an order corresponding to the order of a repair procedure defined in an aircraft component maintenance manual.

Any suitable technique can be used for affixing the part labels to the package face. For example, the part labels can be affixed using a suitable adhesive. In other embodiments the part labels could be formed directly on the package face. Furthermore, it should be noted that steps 204 and 206 can be performed in any order. For example, in many typical embodiments the plurality of labels would be affixed to the package face before placement of parts in the package chambers.

Turning now to FIG. 3, a schematic diagram illustrates an exemplary relationship between an aircraft part 302 as identified in a portion of component maintenance manual page 304 and a corresponding label 306 on the package face 308. As can be seen in FIG. 3, the package face 308 includes a plurality of labels, with each label identifying a corresponding part (e.g., aircraft part 302). Again, the labels (e.g., label 306) and parts (e.g., aircraft part 302) are arranged in an order corresponding to the order of use in a defined repair procedure. For example, in an order corresponding to the order of a repair procedure defined in an aircraft component maintenance manual. And with the labels and parts so arranged, the defined repair procedure can be performed as described in an associated component maintenance manual.

It should be noted that in this example each label includes various part identifiers, including a part numbers and a part names, along with other relevant information. Of course, this is just one example of the types of information that can be included on the part labels.

Turning now to FIGS. 4, 5 and 6, another example embodiment of package 400 is illustrated. In this embodiment the package 400 includes an outer package 402 that holds a package body 404, also referred to as a package tray. The package body 404 includes a package face 406 having labels 408 and a plurality of chambers 410. The outer package 402 is configured to receive the package body 404 and includes a lid 412 to hold parts in the chambers 410 of the package body 404.

FIG. 4 illustrates a perspective view of the package 400 with the lid 412 closed. Again, with the lid 412 closed parts are secured in their corresponding chamber. FIG. 5 illustrates a perspective view of the package 400 with the lid 412 open, exposing the chambers 410. Finally, FIG. 6 illustrates a perspective view of the package 400 with the package body 404 propped up in a position that facilitates mechanic access to parts within the chambers 410.

In package body 404, the chambers 410 are configured to contain at least one vehicle part separate from other parts. Each of the labels 408 identifies one of the parts in the corresponding chamber 410, and the labels 408 are affixed to the package face 406 proximate to the chamber 410 containing the corresponding part. To facilitate time efficient use by a mechanic performing a repair procedure, the package labels 408 and the parts in the chambers 410 are arranged in an order of use in the repair procedure. Thus, the mechanic can easily find and retrieve the next part to be used to during the repair procedure.

It should be noted that in this example one package body 404 fits inside the outer package 402. However, this is just one example, and in other examples multiple package bodies 404 may fit inside one outer package 402. In these embodiments the package bodies 404 can be configured to fit side by side or stacked on top of each other. And again, in such an arrangement, the parts could be ordered with different types of parts in different package bodies 404.

In the embodiments described above, the physical design of the package and labels directs the user to locate and install parts in the exact order illustrated by the corresponding component maintenance manual. Specifically, the placement of parts and their respective chambers in the package reflect the order with which the parts are installed in the repair procedure, thus alleviating the potentially time consuming need for the mechanic to pull out and arrange the parts of the work bench prior to starting the repair procedure.

Furthermore, because the order/placement of the parts in the package corresponds to the their use in the manual defined procedure, the probability of a successful, high quality install by mechanics, whom may have no prior knowledge of the component being repaired, is much easier to achieve. Furthermore, the use of such packaged parts can standardize the usage of parts necessary to complete a specific type of repair and thus reduces risk from mechanics discretion. Finally, the use of such packaged parts can assist the customer with traceability (i.e., the customer will know what parts were used and replaced).

The foregoing description of specific embodiments reveals the general nature of the inventive subject matter sufficiently that others can, by applying current knowledge, readily modify and/or adapt it for various applications without departing from the general concept. Therefore, such adaptations and modifications are within the meaning and range of equivalents of the disclosed embodiments. The inventive subject matter embraces all such alternatives, modifications, equivalents, and variations as fall within the spirit and broad scope of the appended claims. 

What is claimed is:
 1. A package comprising: a package body, the package body including a package face; a plurality of chambers defined in the package body, each of the plurality of chambers configured to contain at least one vehicle part; and a plurality of part identifiers, each of the plurality of part identifiers identifying one of a plurality of vehicle parts, the plurality of part identifiers arranged on the package face with each of the plurality of part identifiers proximate to a corresponding one of the plurality of chambers to identify a corresponding vehicle part, and where the plurality of part identifiers are arranged in an order on the package face corresponding to an order of use during a vehicle repair.
 2. The package of claim 1, wherein each of the plurality of part identifiers includes a visual indicator that corresponds to another visual indictor found in a manual describing the vehicle repair.
 3. The package of claim 2, wherein the visual indicator and the another visual indicator comprise a similar color.
 4. The package of claim 2, wherein the visual indicator and the another visual indicator comprise a similar shape.
 5. The package of claim 1, wherein the vehicle repair is described in a component maintenance manual.
 6. The package of claim 1, wherein the vehicle repair comprises an aircraft repair procedure.
 7. The package of claim 1, wherein the plurality of chambers are defined using controlled cuts in the package face.
 8. The package of claim 1, wherein each of the plurality of chambers include an insert to define an interior space.
 9. The package of claim 1, wherein the package includes a reference to a manual defining the vehicle repair.
 10. The package of claim 9, wherein the reference comprises a QR code.
 11. The package of claim 1, wherein the package further includes: a second package body, the second package body including a second package face; a second plurality of chambers defined in the second package body, each of the second plurality of chambers configured to contain at least one vehicle part; and a second plurality of part identifiers, each of the second plurality of part identifiers identifying one of the plurality of vehicle parts, the second plurality of part identifiers arranged on the second package face with each of the second plurality of part identifiers proximate to a corresponding one of the second plurality of chambers to identify a corresponding vehicle part, and where the second plurality of part identifiers are arranged in an order on the second package face corresponding to an order of use during the vehicle repair.
 12. The package of claim 11, wherein the package body and the second package body are configured to stack in the package.
 13. The package of claim 11, wherein the package body is labelled for hard parts, and wherein the second package body is labelled for soft parts.
 14. A package for delivering a plurality of aircraft parts, the package comprising: a package body, the package body including a package back and a package face; a plurality of chambers defined in the package body, each of the plurality of chambers configured to contain one of the plurality of aircraft parts separate from other of the plurality of aircraft parts contained in the package body; and a plurality of part labels, each of the plurality of part labels identifying one of the plurality of aircraft parts, the plurality of part labels affixed to the package face with each of the plurality of part labels positioned proximate to a corresponding one of the plurality of chambers to identify a corresponding one of the plurality of parts contained in the corresponding one of the plurality of chambers, and where the plurality of part labels are arranged in an order on the package face corresponding to an order of use in a defined repair procedure that uses the plurality of aircraft parts, and wherein the defined repair procedure is described in a component maintenance manual.
 15. The package of claim 14, wherein each of the plurality of part labels includes a visual indicator that corresponds to another visual indictor found in the component maintenance manual describing the defined repair procedure.
 16. The package of claim 14, wherein the plurality of chambers are each defined using controlled cuts in the face, and wherein each of the plurality of chambers include an insert to define an interior space.
 17. A method of packaging a plurality of aircraft parts for delivery to a repair facility, the method comprising: providing a package, the package including a package face and a plurality of chambers, each of the plurality of chambers configured to contain one of the plurality of aircraft parts separate from other of the plurality of aircraft parts contained in the package; placing at least one of the plurality of aircraft parts in each of the plurality of chambers; and affixing a plurality of part labels to the package face, each of the plurality of part labels identifying one of the plurality of aircraft parts, with each of the plurality of part labels positioned proximate to a corresponding one of the plurality of chambers to identify a corresponding one of the plurality of aircraft parts contained in the corresponding one of the plurality of chambers, and where the plurality of part labels are arranged in an order on the package face corresponding to an order of use in a defined repair procedure that uses the plurality of aircraft parts.
 18. The method of claim 17, wherein each of the plurality of part labels includes a visual indicator that corresponds to another visual indictor found in a component maintenance manual describing the defined repair procedure.
 19. The method of claim 18, further comprising the step of performing the defined repair procedure as described in the component maintenance manual.
 20. The method of claim 17, wherein the providing the package comprises defining the plurality of chambers using controlled cuts in the face, and adding an insert to each of the plurality of chambers to define an interior space. 